Senior Engineer, Production (APC)

JOB PURPOSE

The jobholder is responsible to implement and support Advanced Process Control & Real Time Optimizer (APC / RTO) systems to maximize efficiency and better production performance as per the plant specifications. This role includes implementing and supporting Advanced Process solutions like APC monitoring system, Plant Digital Twin (PDT), and Operator Training Simulator (OTS) systems, providing support to operations for plant assets safety and reliability. Collecting and analyzing data to monitor current processes, optimizing processes, and developing new processes. Providing expertise at a process level for cost reduction. Performing systematic checks and upgrading systems periodically to avoid obsolescence issues. Analyzing plant requirements and implementing appropriate solutions. Ensuring systems performance and availability by following established procedures.

KEY ACCOUNTABILITIES

Process Optimization

1. Analyze production processes to identify inefficiencies and recommend improvements, ensuring optimal performance and cost-effectiveness.
2. Implement advanced process control strategies to enhance production stability and product quality, aligning with Borouge's operational goals.
3. Monitor key performance indicators (KPIs) to track process performance and identify areas for improvement, supporting continuous improvement initiatives.
4. Collaborate with cross-functional teams to develop and implement process optimization projects, ensuring alignment with business objectives.
5. Conduct root cause analysis of process deviations to prevent recurrence, maintaining operational excellence and utilizing data analytics tools to gain insights into process performance, driving data-driven decision-making.

Safety Compliance

1. Ensure adherence to safety standards and regulations in all production activities, safeguarding employee well-being and operational integrity.
2. Conduct safety audits and inspections to identify potential hazards and implement corrective actions, promoting a safe working environment.
3. Develop and implement safety training programs for production staff, enhancing safety awareness and compliance.
4. Investigate safety incidents and near-misses to identify root causes and implement preventive measures, reducing the risk of future incidents.
5. Collaborate with the HSE department to ensure compliance with Borouge's safety policies and procedures, maintaining a culture of safety.
6. Maintain accurate safety records and documentation, ensuring compliance with regulatory requirements.

Quality Assurance

1. Develop and implement quality control procedures to ensure product consistency and compliance with specifications, meeting customer expectations.
2. Collaborate with the quality assurance team to investigate and resolve customer complaints, ensuring customer satisfaction.
3. Monitor and analyze quality data to identify trends and areas for improvement, driving quality improvements.

Cost Management

1. Monitor production costs and identify opportunities for cost reduction, supporting Borouge's financial objectives.
2. Recommend cost-saving initiatives and process improvements to enhance operational efficiency, reducing production expenses.
3. Collaborate with the finance team to develop and manage production budgets, ensuring cost control and accountability.
4. Analyze cost data to identify trends and areas for improvement, driving cost optimization efforts.
5. Develop and implement strategies to reduce waste and improve resource utilization, supporting sustainable operations.
6. Ensure compliance with financial policies and procedures, maintaining financial integrity and transparency.

Stakeholder Collaboration

1. Collaborate with internal and external stakeholders to ensure the alignment of production activities with business objectives, supporting Borouge's strategic goals.
2. Communicate effectively with cross-functional teams to ensure seamless coordination and execution of production plans, enhancing operational efficiency.
3. Develop and maintain strong relationships with key stakeholders, including suppliers, customers, and regulatory authorities, ensuring effective collaboration.
4. Participate in cross-functional meetings and projects to provide input and support, contributing to overall business success.
5. Address stakeholder concerns and issues promptly and effectively, maintaining positive relationships and trust.
6. Ensure alignment of production activities with customer requirements and expectations, supporting customer satisfaction and loyalty.

Innovation & Technology

1. Stay updated on industry trends and technological advancements to identify opportunities for innovation, supporting Borouge's competitive edge.
2. Suggest new technologies and automation solutions to enhance production efficiency and quality, driving operational excellence.
3. Ensure compliance with technology standards and best practices, maintaining Borouge's technological leadership.

Borouge Corporate Responsibilities

1. To keep abreast and knowledgeable about his / her role contribution towards the areas of Health, Safety Environment (HSE), Sustainability, Energy Management, Ethics & Regulations, and Quality Management and its respective policies, frameworks, procedures, and objectives.
2. Comply, support and enrich the culture and understanding of it through his / her communications with the internal and external contacts.
3. Participate and contribute to the design, development and establishment of an Integrated Risk Management Framework within the Unit while identifying and assessing relevant domain risks and implement measures to manage and mitigate all identified risks within the function.
4. Ensure corporate business ethics and the Company's Code of Conduct are communicated to employees within the function in compliance with the Corporate Policies and guidelines.

Departmental Plans

1. Plan, supervise and coordinate all activities in the assigned processes / area to meet functional objectives.
2. Provide input for preparation of the section / department budgets and assist in the implementation of the approved Budget and work plans to deliver the respective objectives.
3. Contribute to the achievement of the approved Performance Objectives for the section / department in line with the company's performance framework, and KPIs.
4. Analyze and address any significant variances to support effective performance and cost control.
5. Review, prepare, and recommend the required reports on work activities, projects, processes, etc. to next level manager in line with business requirements.

Processes & Systems

1. Implement approved the respective policies, processes, systems, standards and procedures to support execution of the work programs.
2. Perform analysis on the respective processes and activities to ensure timely availability of the data analysis within the respective areas.
3. Train and develop the assigned staff in relevant skills to enable them to become proficient in the job and deliver the respective section objectives.
4. Provide feedback on the updating and implementation of new tools and techniques to improve the quality and efficiency of processes.
5. Identify improvements in internal processes against best practices in pursuit of greater efficiency in line with ISO standards to define intelligent solutions for issues confronting the function.
6. Adhere to professional business relations and commercial responsibilities in the areas of customer delight, data confidentiality, business communications and representation, and Borouge's corporate image.

QUALIFICATIONS, EXPERIENCE, KNOWLEDGE & SKILLS

Minimum Qualification

1. Bachelor's Degree in Chemical Engineering, Polymers, or any related Engineering or Science Disciplines.
2. Preferably, Master's Degree in Chemical Engineering, Automation or Process Engineering or equivalent qualifications.
3. Fluency in English language; written and oral with excellent communication skills.

Minimum Experience & Knowledge & Skills

1. Minimum of 5 - 8 years' experience in Advanced Process Control, preferably in the refinery or petrochemical industry.
2. Hands-on and theoretical training certificates on DCS system.
3. Problem solving skills and the ability to perform root cause analysis.
4. Knowledge of system diagnostic capabilities, back-up routines to be followed.
5. Knowledge of process alarm rationalization methods.
6. Implementation of APC on process plant including entire project cycle i.e. proposal, functional design, step test, modeling, reviews, DCS configuration & benefit studies.
7. Technical Competencies in using APC software like DMC3, Honeywell RMPCT, PACE, etc.
8. Expert in using process modeling software like Unisim / Hysys & OTS.
9. Good knowledge in Process Engineering principles and understanding of relevant requirements and standards.
10. Advanced skills in Microsoft Excel for performance monitoring, analyses and verification.
11. Expertise in decision analysis, troubleshooting, strategy assessment, techno-economic analysis and report writing.

Professional Certifications

1. Preferred to be certified in one or more of the following certifications: Certified Six Sigma Black Belt or Green Belt.
2. Project Management Professional (PMP) or equivalent certification.